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MackTheKnife's 924 Turbo Build Thread

 
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Fri Jul 25, 2014 1:36 pm    Post subject: MackTheKnife's 924 Turbo Build Thread Reply with quote

Hi all,

I'm new on here and want to share the progress of fixing up my 1980 924 turbo.

I'm not totally sure where or if the resto job will end. All I know is the mighty '24 turbo has been my favourite Porsche for quite some time.

Many years ago I had an '81 model in white. It was sold many years ago to buy an MX-5 (Miata) that the wife could drive as well. She drove the MX-5 once for about 5 kms just after we got it and never again. In truth I should have rented her an MX-5 so she could have driven it 5 km and got that out of her system.

This is my old one:


After a rotten week at work a couple of weeks ago, I told the wife I deserve to buy another Porsche. She suggested a project and spotted my new one on eBay.

So on Wednesday, I rented a trailer and picked it up with my Pajero (a name which will amuse spanish speakers out there).



So this is it, where it sits.









No interior shots or engine shots since it the seats are ratty and the engine is looking real rough at the moment. The body and paint are in great condition though.

One thing i'm debating whether to keep the front mount intercooler that's been fitted or put it back to stock.

The first jobs though will be:

* Wash inside and out
* Adjust Drivers Door lock and lube all locks
* Check fuel system
* Replace vacuum hoses
* See if it starts without someone manipulating the CIS

After that it'll be a long slow restoration.
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Paul Mc - Proud owner of:

'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed
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morghen  



Joined: 21 Jan 2005
Posts: 8167
Location: Romania

PostPosted: Fri Jul 25, 2014 4:09 pm    Post subject: Reply with quote

nice looking car !
keep the intercooler.

Pajero
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Ruby-sh 924
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kcoyle  



Joined: 15 Jan 2011
Posts: 712
Location: Long Island, NY

PostPosted: Sat Jul 26, 2014 7:26 am    Post subject: Reply with quote

morghen wrote:
nice looking car !
keep the intercooler.

Pajero


+1!!
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1982 931- Stock with MBC at 8psi

Relax, all right? My old man is a television repairman, he's got this ultimate set of tools. I can fix it.
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Sat Jul 26, 2014 5:03 pm    Post subject: Reply with quote

Yep, front mount is staying for sure now.

Good day today, had a rummage through the engine bay looking for cracked hoses, loose wires etc. A stand out item was the dizzy,which was loose.

I set the dizzy as described in a thread in this forum and gave it a kick.

No good yet, so the wife turned the key and I pressed the plate on the CIS. It fired up but wouldn't idle.

I checked the idle screw and it was just short of being fully tight. I backed it off a bit and hey presto, we have a runner.



Next job is refreshing everything made of rubber in the engine bay. Fluids seem new, they can wait a bit.
http://youtu.be/j9Ul-pVrlog
http://youtu.be/8QYWSm6X8YY
http://youtu.be/2f46jpVI5IQ
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Paul Mc - Proud owner of:

'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed
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macBdog  



Joined: 16 Aug 2004
Posts: 1111
Location: Brisbane, Australia

PostPosted: Sun Jul 27, 2014 1:00 pm    Post subject: Reply with quote

Hey Mack!

Really interesting project. When I bought my 79 Turbo in Brisbane it had a really similar looking intercooler setup right down to the bashed in pipe behind the right headlight. Maybe there was an Australian shop fitting intercoolers to these cars back in the day?

Best of luck with it!
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1979 931 with a 350 chev
1973 911E with EFI
p-talk wrote:
I'm still convinced the word 'Porsche' makes people crazy in all kinds of ways
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Sun Aug 03, 2014 7:06 pm    Post subject: Reply with quote

Pretty full on day today, with an added hangover from a good friends birthday party last night.

Replaced all the big vacuum hoses and elbows. One elbow had previously been replaced with straight hose which had kinked.

There were plenty of cracks in the old hoses, so have definitely sorted out a few leaks.

The car starts much easier now. Also it used to idle at 950 odd rpm. It now revs higher when the engine is cold and reduces as the motor warms up.

I also degreased the topside of the engine and one side of the gearbox. I'll do the rest when I have some dry ground to lie on.

Next job will be the timing belt, tensioner and small vacuum hoses.
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Paul Mc - Proud owner of:

'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Wed Aug 06, 2014 2:11 pm    Post subject: Reply with quote

Timing belt, tensioner and vacuum hoses have all been done. Fixed a small fuel leak along the way.

Added some paint too:

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'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed
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morghen  



Joined: 21 Jan 2005
Posts: 8167
Location: Romania

PostPosted: Wed Aug 06, 2014 3:07 pm    Post subject: Reply with quote

wow, why that blue? black or even silver would have matched the car much better.
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Wed Aug 06, 2014 7:14 pm    Post subject: Reply with quote

It'll make sense later.
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Paul Mc - Proud owner of:

'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Sun Aug 10, 2014 8:04 pm    Post subject: Reply with quote

This weekend was mostly spent changing the oil. The sump plug is totally stuck, so I got the old oil out through the oil cooler return hole using an oil pump. A fumoto valve has been ordered to replace the plug next service.

The oil filter was stuck pretty well too but I managed to force an oil filter wrench onto it and removed and replaced it.

Anyways, I managed to run the car with oil flush additive, dump the old oil, then fill with cheap oil, run it again, empty and add new oil and filter. I opted for 10w 40 full synthetic this time around. Also sorted out a water leak, change the water and bled air out of the system.

Took it for a short spin with my assistant (my 6 year old son Connor helps me out).

I then got all of the lights working.

I need to fine tune the timing and mixture soon.

Next job will be the gearbox seals and oil.
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Paul Mc - Proud owner of:

'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed
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Rasta Monsta  



Joined: 12 Jul 2006
Posts: 11378
Location: PacNW

PostPosted: Mon Aug 11, 2014 1:19 am    Post subject: Reply with quote

morghen wrote:
wow, why that blue?


Because blue is awesome:


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  • Red (1987 924S) - Pro44/Spec944
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Wed Aug 13, 2014 10:11 am    Post subject: Reply with quote

Nice engine bay Rasta!!
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Paul Mc - Proud owner of:

'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed
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MackTheKnife  



Joined: 22 Jul 2014
Posts: 12
Location: Central Coast NSW Australia

PostPosted: Sun Aug 31, 2014 9:36 pm    Post subject: Reply with quote

Not alot happened the last few weeks, thanks to constant rain. Just really tidied up the interior a bit and added some temporary seat covers.

Today I decided to tackle the gearbox. I spent a couple of hours chasing a 17mm hex tool with no success.

Plan B was to fix the plastic trim under the doors. It was screwed and glued on, badly. I took it off and was pleased not to find much rust under there.

I wire wheeled off the surface rust that was there as well as a bit in the rear wheel wells. Then attacked those areas with rust converter. The area under the trim and the wheel wells were then treated to three generous coats of underbody paint.

Thankfully all of the attachments for the plastic trim were intact. I enlisted the wife to help put the trim on properly. It was slid on from back to front, assisted with a hammer for the last little bit.

I ordered the 17mm hex tool from eBay, so I can tackle the gearbox shortly.

All that's left to do mechanically is the water pump, new bushings for the front, ball joints and tie rod ends. Also have to tackle the horn, and add a windshield water reservoir. After that it'll be only cosmetic work.
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Paul Mc - Proud owner of:

'80 924 Turbo (ROW)
'12 VW Polo GTI
'00 Mitsubishi Pajero Exceed


Last edited by MackTheKnife on Wed Feb 11, 2015 8:18 am; edited 1 time in total
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Fasteddie313  



Joined: 29 Sep 2013
Posts: 1940
Location: MI

PostPosted: Sun Aug 31, 2014 9:52 pm    Post subject: Reply with quote

my local napa happened to have a vw specific special trans drain plug tool..

like a 17mm od hex with a 3/8 ratchet drive in its backside....

I planned on just cutting down a 17mm allen wrench to use in conjunction with a boxed end spanner but the tool was cheaper than a regular allen wrench actually .. like $6 but sadly tiawan..
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Joes924Racer  



Joined: 03 Nov 2002
Posts: 11964
Location: Oregon, Denver Colorado native!

PostPosted: Mon Sep 01, 2014 4:43 pm    Post subject: Reply with quote

Just 1 of the pitas involved in owning a old bag of nostalgia such as our cars.





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1980 porsche Turbo 931GT Replica
Have u ever driven a turbo.
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